CN106573415A - 感应加热装置 - Google Patents

感应加热装置 Download PDF

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Publication number
CN106573415A
CN106573415A CN201580031130.4A CN201580031130A CN106573415A CN 106573415 A CN106573415 A CN 106573415A CN 201580031130 A CN201580031130 A CN 201580031130A CN 106573415 A CN106573415 A CN 106573415A
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China
Prior art keywords
magnetic insert
induction heating
magnetic
coil
insert
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CN201580031130.4A
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CN106573415B (zh
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帕尔·比尔莱因
马汀·亚历山大松
丹尼尔·桑德伯格
卡尔·伊斯拉埃尔松
路易斯·卡利奥
文森索·德萨尔沃
卡尔-阿克塞尔·约翰逊
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Tetra Laval Holdings and Finance SA
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Tetra Laval Holdings and Finance SA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3668—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the means for supplying heat to said heated elements which remain in the join, e.g. special induction coils
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3604—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint
    • B29C65/3656—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the type of elements heated by induction which remain in the joint being a layer of a multilayer part to be joined, e.g. for joining plastic-metal laminates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/34—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
    • B29C65/36—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction
    • B29C65/3672—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint
    • B29C65/3676—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint being metallic
    • B29C65/368—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated elements which remain in the joint, e.g. "verlorenes Schweisselement" heated by induction characterised by the composition of the elements heated by induction which remain in the joint being metallic with a polymer coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/3472—General aspects dealing with the joint area or with the area to be joined using particular temperature distributions or gradients; using particular heat distributions or gradients in the plane of the joint, e.g. along the joint line in the plane of the joint or perpendicular to the joint line in the plane of the joint
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/431—Joining the articles to themselves
    • B29C66/4312—Joining the articles to themselves for making flat seams in tubular or hollow articles, e.g. transversal seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/431—Joining the articles to themselves
    • B29C66/4312—Joining the articles to themselves for making flat seams in tubular or hollow articles, e.g. transversal seams
    • B29C66/43121—Closing the ends of tubular or hollow single articles, e.g. closing the ends of bags
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7232—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer
    • B29C66/72321—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer consisting of metals or their alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8122—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8126—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/84—Specific machine types or machines suitable for specific applications
    • B29C66/849—Packaging machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B51/00—Devices for, or methods of, sealing or securing package folds or closures; Devices for gathering or twisting wrappers, or necks of bags
    • B65B51/10—Applying or generating heat or pressure or combinations thereof
    • B65B51/26—Devices specially adapted for producing transverse or longitudinal seams in webs or tubes
    • B65B51/30—Devices, e.g. jaws, for applying pressure and heat, e.g. for subdividing filled tubes
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/10—Induction heating apparatus, other than furnaces, for specific applications
    • H05B6/105—Induction heating apparatus, other than furnaces, for specific applications using a susceptor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/745—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using a single unit having both a severing tool and a welding tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
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    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
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    • B65B9/20—Enclosing successive articles, or quantities of material, in preformed tubular webs, or in webs formed into tubes around filling nozzles, e.g. extruded tubular webs the webs being formed into tubes in situ around the filling nozzles

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • General Induction Heating (AREA)
  • Soft Magnetic Materials (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

提供了一种用于增强感应加热装置的磁场的磁性插入件。磁性插入件(302)通过使用包含能模制聚合物基体和软磁性材料的组合物制造。

Description

感应加热装置
技术领域
本发明涉及一种感应加热装置和一种用于这种感应加热装置的磁性插入件。特别地，本发明涉及一种用于对具有导电层的包装提供横向密封的感应加热装置以及用于提供该感应加热装置的方法。
背景技术
在液体产品包装中，例如在液体食品包装中，通常使用基于纸板的包装材料来形成最终包装。图1示出了这种系统的示例。包装材料可以设置为用于在灌装机中产生单独的包装的单个片材，或者作为馈送到灌装机中的材料幅材。包装材料幅材通常以大辊7来分配，其中灌装机被配置成馈送包装材料3通过多个处理站，例如灭菌器、成型部8、灌装部10，以及灌装机的分配部。
包装材料可以形成为开口端管。该管竖直地布置在灌装机10中，并且当包装材料被输送通过灌装机时，该管经受连续灌装。当包装材料移动并且因此管移动时，提供横向密封件14用于形成管的单个包装。通过操作密封钳14以在密封区域中也提供横向切口，将每个包装与管分离，并且运送单个包装15以允许随后的包装与管分离。
管通过将包装材料的横向端部布置成使得它们重叠并且通过将横向端部彼此密封以在横向端部之间形成流体密封连接而形成。
用于横向密封的感应加热装置通常由五个单独的部件组成，如图2所示。通常由铝制成的基座结构201支撑通常由聚苯硫醚(PPS)制成的安装芯202。多个软磁材料插入件203设置在安装芯上，用于局部地增强感应加热装置的磁场，从而提高在包装的导电层处的感应功率，从而导致功率的局部增大约30％。线圈204布置在插入件203的邻近处，并且最后主体结构205包围所有其他部件。类似于安装芯202，主体结构205可以由PPS制成。通常，这种电感加热装置20通过将基座结构201、芯202、(多个)插入件203和线圈204一起安装在模具中，然后在安装的部件上注射模制主体结构205来制造。
直到今天，通过将软磁材料烧结成刚性件来制造磁性插入件203。烧结过程是非常昂贵的方法，需要先进的设备，同时限制插入件203的形状的设计自由度。
此外，已知的感应加热装置具有有限的预期寿命。随着时间的推移，由于向提供横向密封所需的包装材料卷的间歇性按压操作，主体结构变得疲劳。
因此，用于磁性插入件以及利用这种磁性插入件的感应加热装置的改进的解决方案将是有利的。
发明内容
因此，本发明的目的是克服或缓解上述问题。
根据第一方面，提供了一种用于增强感应加热装置的磁场的磁性插入件。通过使用包含能模制的聚合物基体和软磁性材料的组合物制造磁性插入件。
在一个实施方式中，能模制的聚合物基体包含PPS，PPS是被证明在高速应用中(例如当在液体食品包装中提供横向密封时)有效的耐用材料。
软磁性材料可以包括NiZn铁氧体。软磁性材料的浓度可优选在30-70体积百分比的范围内。根据特定应用，需要不同性质的磁性插入件，因为相对高百分比的聚合物基体，所选择的间隔已经证明允许有效的制造，同时仍提供期望的渗透性。
聚合物基体可以优选是能注射模制的、能热成型的和/或能转移模制的。在其他实施方式中，可以使用可购得的3D打印机选择可印刷的聚合物基体。
根据第二方面，提供一种用于制造用于感应加热装置的磁性插入件的方法。该方法包括提供包含能模制的聚合物基体和软磁性材料的组合物，以及将所述组合物形成为所述磁性插入件的步骤。
形成所述组合物的步骤可以通过注射模制、热成型、转移模制或3D打印来进行。
根据第三方面，提供了一种用于密封两层包装材料的感应加热装置。所述感应加热装置包括：基座结构，其支撑根据第一方面所述的磁性插入件；线圈，其用于感应磁场并且布置在所述磁性插入件的与所述基座结构相对的一侧；以及主体结构，其被布置成在组装时包围所述磁性插入件和线圈。
磁性插入件可以被注射模制在基座结构和线圈之间。
在一个实施方式中，磁性插入件在基座结构的面向线圈的顶表面上延伸。
磁性插入件可以形成有用于接收线圈的凹槽图案。
在优选实施方式中，基座结构由不锈钢制成。
磁性插入件可以布置成在其顶表面上具有至少一个圆形、斜面或倒角的突起，并且在一些实施方式中，磁性插入件沿着线圈的长度延伸。
根据第四方面，提供了一种制造感应加热装置的方法。该方法包括以下步骤：将基座结构和线圈安装在第一模具中；在所述基座结构和所述线圈之间注射模制根据第一方面所述的磁性插入件，产生第一部件；将所述第一部件安装在第二模具中；以及将主体结构注射模制到所述第一部件上，从而形成所述感应加热装置。
该方法还可以包括形成不锈钢的基座结构的步骤。
附图说明
通过以下参照附图对本发明的优选实施方式的说明性和非限制性的详细描述，将更好地理解本发明的上述目的、特征和优点以及其它目的、特征和优点，其中：
图1是现有技术的液体产品灌装机的示意图；
图2是用于在包装上提供横向密封的现有技术的感应加热装置的示意图；
图3是根据一个实施方式的电感器加热装置的示意图；
图4是根据一个实施方式的设置有圆形突起的磁性插入件的示意性侧视图；以及
图5是根据一个实施方式的方法的流程图。
具体实施方式
作为一般原理，与先前已知的解决方案相比，形成包括可模制聚合物基体和软磁性材料的组合物的磁性插入件的所提出的解决方案将导致许多益处。首先，材料的选择将允许能通过诸如注射成型等的高速设备来生产磁性插入件。此外，对于形状和尺寸不再有约束，由此磁性插入件的尺寸可以自由设计。
考虑到这些优点，一个想法是提供机械强度更大并且设计灵活的感应加热装置。考虑到使用PPS的常见解决方案，通过提供具有提高的耐久性的基座结构的感应加热装置来实现该想法。这种基座结构可以是金属材料，例如不锈钢。
为了不负面影响感应加热能力，金属基座结构优选通过磁屏蔽件与线圈屏蔽。为此，磁屏蔽件应沿着线圈的长度延伸，使得屏蔽件在线圈和基座结构之间形成物理屏障。由于用于提供磁性插入件的新颖技术，已经认识到，作为细长结构提供的这种磁性插入件实际上可以以非常有效的方式形成这种屏蔽。因此，所提出的磁性插入件不仅允许更有效的制造，而且允许感应加热装置的金属基座，该金属基座直到今天仍是不可行的。
为了能够使用感应在包装上提供横向密封，包装设置有与由感应加热装置产生的磁场相互作用的导电层。这种相互作用将在包装材料的导电层中产生涡流，由于导电层的固有电阻将在密封位置处局部地升高包装材料中的温度，由此温度升高用于使用于将包装材料层压的包装材料的聚合物层熔化。
在一个实施方式中，参照图3，示出了感应加热装置30。感应加热装置包括基座结构301，基座结构301优选地由刚性和耐用的金属材料(例如不锈钢)形成。感应加热装置30还包括布置在基座结构301上的磁性插入件302。磁性插入件302由包括可模制聚合物基体和软磁性材料的组合物形成。优选地，软磁材料的浓度选择为在30-70体积百分比的间隔中，并且在更优选的实施方式中，在50-70体积百分比之间。
线圈303在与基座材料相对的一侧上布置在磁性插入件302上，由此磁性插入件302用于屏蔽金属基座结构与线圈。当电流流过线圈303时，由提供软磁性材料引起的磁性插入件302的磁性将实际上提高感应加热装置30的效率。由于磁性插入件302的软磁性材料影响磁性插入件的磁导率，较高的磁导率允许更多的磁场通过它，即较少的磁场逸出到不锈钢主体中，从而将导致热损失。
此外，感应加热装置30包括主体结构304，主体结构304布置成紧邻线圈303，并且被设置以形成刚性主体。主体结构应优选地由能够承受重复荷载(例如当在高速灌装机中使用时的情况)的刚性材料制成。因此，主体结构304可以由包括PPS和玻璃纤维的复合物制成，优选地通过将复合物注射模制到容纳基座结构301、磁性插入件302和线圈303的模具中来制造。
磁性插入件302包括软磁性材料。用于磁性插入件302的材料可以由于特定应用的具体要求而选择。例如，磁性插入件302可以由包括PPS和NiZn铁氧体的化合物形成，其中NiZn铁氧体的浓度在30体积百分比和70体积百分比之间，优选在50体积百分比和70体积百分比之间。
磁性插入件的功能至少是双重的。首先，屏蔽金属基座结构301，从而防止或至少限制在使用中对与线圈相关联的磁场产生负面影响。其次，磁性插入件302的软磁性材料用于增强线圈的磁场，或者换句话说，允许将磁场成形为期望形状，这允许改进的横向密封功能。因此，使用磁性插入件302，不需要像在已知解决方案中那样使用单独的插入件。
在一个实施方式中，磁性插入件的软磁性材料包括具有软磁性颗粒的聚合物基体。聚合物基体可以包括聚苯硫醚(PPS)，由此磁性插入件392可以通过如注射模制、热成型、传递模制、3D打印等各种技术模制。
在一个实施方式中，磁性插入件302在面向线圈303的基座结构301的顶表面上延伸。
在一个实施方式中，磁性插入件302布置成这样的形状，使得当线圈303布置在磁性插入件302中时，磁性插入件302在从线圈303到基座结构301的任何线性方向上将线圈303与基座结构301屏蔽。
在一个实施方式中，磁性插入件302具有带有凹槽图案的形状，所述凹槽图案用于接收线圈303，优选地紧密配合。凹槽图案优选地在基本上沿着磁性插入件302的整个长度在磁性插入件302的中心部分中延伸，使得凹槽图案可以通过部分地围绕线圈303模制磁性插入件302而形成。
在一个实施方式中，磁性插入件302是可注射模制的。通过利用注射模制，磁性插入件302可以直接模制到线圈303，从而提高电感器的效率。关于目前的解决方案，因为去除了对单独插入件的需要，注射模制的磁性插入件302减少了内部部件的数量。因为注射模制的材料将具有更均匀的用于灌装的体积，减少数量的内部部件使得设计更加坚固。此外，由于去除了手动安装插入件的需要，因此减少了制造时间。由于减少了手工劳动，也降低了在制造期间错误的风险。
磁性插入件302可以通过利用其中安装有基座结构301和线圈303的注射成型工具来注射成型。由于磁性插入件302在注射模制工具中的注射模制过程中直接成形，可以避免容差链问题。
磁性插入件302的注射模制还使得能够在密封关键区域中进行补偿，因为可以选择磁性插入件302的形状，使得增大数量的材料被布置在关键位置处，例如在侧向端部以及在纵向密封重叠的位置。
在一个实施方式中，基座结构由不锈钢制成。由不锈钢制成的基座结构比通常已知的铝基座结构具有更好的寿命预期。优选地，基座结构不应是磁性的，因为这将不利地影响电感器的效率。根据最终应用的要求，应选择一种材料。铝可以非常好地完全适合于环境条件不太严苛的一些应用。在现有技术的解决方案中，由于烧结工艺的制造，磁体插入件302具有尖锐的过渡。由于这样的尖角可能导致聚合物主体205中的裂纹和材料疲劳，因此这种尖角限制了设计选择的数量。此外，插入件203的锋利边缘可能导致磁场的不期望的分布，由此将发生损耗。
在一个实施方式中，磁性插入件302在其顶表面上布置有多个突起321。突起是圆形、斜面或倒角的，以允许改进的性能，因为这允许定制形成用于横向密封的期望的磁场的形状。换句话说，由于两个原因，突起以平滑过渡布置；i)主体304将具有增加的寿命长度，以及ii)产生的磁场可以具有增加的效率。因此，通过使用注射模制，磁性插入件可以布置成可以沿着磁性插入件的每个点以适当的功率量成形磁场的形式。使用圆形、斜面或倒角的突起进一步降低了由于没有尖角而导致的内部裂纹的风险，这增加了磁性插入件的寿命预期。此外，这种磁性插入件允许在电感器内部减少电阻损耗，从而降低内部温度。
在一个实施方式中，感应加热装置通过双部件模制工艺制造，其中第一部件包括将磁性插入件模制到安装的线圈和基座结构，并且第二部件将使主体结构模制到第一部件上。与已知的解决方案相比，这种制造过程可以自动化达到非常高的程度。
在一个实施方式中，根据图4，提供了制造感应加热装置的方法50。该方法包括将基座结构301和线圈303安装在第一安装件中的步骤51。该方法还包括在基座结构301和线圈303之间注射模制磁性插入件302的步骤52，以产生第一部件。此外，该方法包括将第一部件布置在第二模具中的步骤53和将主体结构304注射模制到第二模具中的第一部件的步骤54，从而形成所述感应加热装置。
尽管上面的描述主要参照用于包装的横向密封的感应加热装置，但是应当理解，所公开的感应加热装置可以用于其中需要通过感应进行密封的许多其它密封应用中。
此外，主要参考几个实施方式描述了本发明。然而，如本领域技术人员容易理解的，除了上面公开的实施方式之外的其他实施方式在由所附权利要求限定的本发明的范围内同样是可行的。

Claims (17)

1.一种用于增强感应加热装置的磁场的磁性插入件，其特征在于，所述磁性插入件(302)通过使用包含能模制的聚合物基体和软磁性材料的组合物制造。
2.根据权利要求1所述的磁性插入件，其中所述能模制的聚合物基体包括PPS。
3.根据权利要求1或2所述的磁性插入件，其中所述软磁性材料包括NiZn铁氧体。
4.根据前述权利要求中任一项所述的磁性插入件，其中所述软磁性材料的浓度为30-70体积百分比。
5.根据前述权利要求中任一项所述的磁性插入件，其中所述聚合物基体是能注射模制、能热成型和/或能传递模制的。
6.根据权利要求1至4中任一项所述的磁性插入件，其中所述聚合物基体是能印刷的。
7.一种用于制造用于感应加热装置的磁性插入件的方法，包括以下步骤：提供包含能模制的聚合物基体和软磁性材料的组合物，以及将所述组合物形成为所述磁性插入件。
8.根据权利要求7所述的方法，其中形成所述组合物的步骤通过注射模制、热成型、传递模制或3D打印进行。
9.一种用于密封两层包装材料的感应加热装置(30)，包括：
基座结构(301)，其支撑根据权利要求1至6中任一项所述的磁性插入件(302)；
线圈(303)，其用于感应磁场并且布置在所述磁性插入件(302)的与所述基座结构(301)相对的一侧；以及
主体结构(304)，其被布置成在组装时包围所述磁性插入件(302)和线圈(303)。
10.根据权利要求9所述的感应加热装置，其中所述磁性插入件(302)被注射模制在所述基座结构(301)和所述线圈(303)之间。
11.根据权利要求9或10所述的感应加热装置，其中，所述磁性插入件(302)在面向所述线圈(303)的所述基座结构(301)的顶表面上延伸。
12.根据权利要求9至11中任一项所述的感应加热装置，其中，所述磁性插入件(302)形成有用于接收所述线圈(303)的凹槽图案。
13.根据权利要求9至12中任一项所述的感应加热装置，其中，所述基座结构(301)由不锈钢制成。
14.根据权利要求9至13中任一项所述的感应加热装置，其中，所述磁性插入件(302)在其顶表面上布置有至少一个圆形、斜面或倒角的突起(321)。
15.根据权利要求9至14中任一项所述的感应加热装置，其中所述磁性插入件(302)沿着所述线圈(303)的长度延伸。
16.一种制造感应加热装置的方法(500)，包括以下步骤：
将基座结构(301)和线圈(303)安装(51)在第一模具中；
在所述基座结构(301)和所述线圈(303)之间注射模制(52)根据权利要求1至6中任一项所述的磁性插入件(302)，产生第一部件；
将所述第一部件安装(53)在第二模具中；以及
将主体结构(304)注射模制(54)到所述第一部件上，从而形成所述感应加热装置。
17.根据权利要求16所述的方法，还包括形成不锈钢的所述基座结构(301)的步骤。
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